Extruded convex plastic panel with standing seams for roof structures

ABSTRACT

An extruded convex plastic panel (100) for use in a metal roof system (118) including a light transmitting member (101) having top and bottom layers (101A, 101B) and a rib structure (102) disposed between the top and bottom layers (101A, 101B). The extruded convex plastic panel (100) further includes a pair of standing seams (103, 106) provided along two opposite side edges of the light transmitting member (101). A pair of connector assemblies (105, 115) provided as a separate unit, which connects the extruded convex plastic panel (100) to the metal roofing system (118) and allows the light transmitting member (101) to expand and contract freely without the use of any fasting devices for connecting the extruded convex plastic panel (100) to the metal roofing system (118).

TECHNICAL FIELD

The present disclosure relates generally to a convex plastic panel used in a roof system and more specifically, an extruded convex light transmitting plastic panel used in a metal roof system.

BACKGROUND

Metal roofing has been a preferred roof covering for residential, commercial, agriculture, institutional and industrial buildings for years. Metal roofing is available in a wide variety of substrates, colors, textures and profiles. Though diverse in appearance, metal roofing has many common attributes such as longevity, allowing water to drain away from the roof surface, durability, recyclability, fire resistance and sustainability.

For buildings with metal roof system, it is often desirable to provide light transmitting plastic panels/skylights to irradiate natural light to the interior of the building by allowing sunlight to enter the building through the light transmitting plastic panels. These light transmitting plastic panels typically have a transparent or translucent sheet material and can come in various shapes including flat, domed, pyramid, trapezoidal or can have a similar profile as that of the metal roof panels. The light transmitting plastic panels normally have connection regions to seal the light transmitting plastic panels to the metal roof system.

Example of such plastic panels is disclosed in U.S. Pat. No. 4,573,300 directed to extruded, plastic panels which are flat with standing seams projecting from the edges of plastic panels at right angle. The plastic panels are joined side by side along the standing seam with a connector assembly and the teeth or locks of standing seams are facing inside the plastic panels for connector assembly engagement.

In another example, U.S. Pat. App. No. US2004/0159054 discloses a light transmitting sheet having a profile similar to that of the metal roofs and includes trapezoidal domes and trapezoidal wings. The light transmitting sheet is attached to the metal roofs by fastening the wings of the light transmitting sheet to the dome of the metal roofs by fasteners. In another example, EP 2,778, 313 discloses a polycarbonate roof skylight of pendentive form and includes connection regions with isolation lugs at both ends of the polycarbonate roof skylight to facilitate the mounting of the polycarbonate roof skylight to the roof.

In the prior art arrangements, the light transmitting plastic panels generally include connection regions provided in the form of metal flaps or wings. These metal flaps are riveted using fasteners or screws to incorporate the light transmitting plastic panels in the metal roof system. This arrangement of incorporating the light transmitting plastic panels in the metal roof system with fasteners has led to several problems.

During a typical day, the metal panels of the metal roof system and its other components will expand and contract because of variations in temperatures. However, due to different coefficients in thermal expansion between the metal panels and the light transmitting plastic panels, there will be a distortion or even cracks, resulting in a leakage within the metal roof system. Since the light transmitting plastic panels are fixed to the metal roof system with screws or fastener, which makes the assembly rigid by not allowing the light transmitting plastic panels to expand or contract freely. But light transmitting plastic panels, such as polycarbonate panels do expand and contract as a linear coefficient of thermal expansion (α) of polycarbonate at 23° C. is 65-70×10⁻⁶/° C., which is extremely high (about 3 times) as compared to metal, thus becoming subject to tensile and compressive forces leading to buckling, distortion or damage of the light transmitting plastic panels.

In view of the foregoing, at least one object is to prevent buckling, distortion or damage of a light transmitting plastic panel or convex plastic panel used with metal roof system. Another object is to provide a convex plastic panel to be installed on the metal roof system by using a connection profile, thus allowing the convex plastic panel to expand or contract freely. Other objects such as desirable features and characteristics will become apparent from the subsequent summary and detailed description, and the appended claims, taken in conjunction with the accompanying drawings and this background.

SUMMARY

Accordingly, it is an object of the present invention to provide a convex plastic panel used in a roof system in order to overcome the disadvantages of the prior art.

It is an object of the present invention to overcome the above disadvantages of the prior art by providing an extruded, convex plastic panel for a metal roof system, which prevents buckling, distortion or damage of the extruded convex plastic panel by eliminating usage of screws, rivets or fasteners for installing the extruded convex plastic panel on the metal roof system.

It is further object of the present invention to provide an extruded, convex plastic panel which will be installed on the metal roof system by using a unique connector assembly, thus allowing the extruded convex plastic panel to expand and contract freely irrespective of the different coefficients of thermal expansion between metal panels used in the metal roof system and the extruded convex plastic panel.

Accordingly, an extruded, convex plastic panel for connecting within a metal roof system is provided. The extruded convex plastic panel includes a light transmitting member, the light transmitting member comprising top and bottom layers and a rib structure disposed between the top and bottom layers. The extruded convex plastic panel further includes a pair of standing seams provided along two opposite side edges of the light transmitting member and projecting downward at angle other than 90 degree.

In an another embodiment, the pair of standing seams provided along two opposite side edges of the light transmitting member; where each of the pair of standing seams is located offset at an offset distance from the two opposite side edges of the light transmitting member.

The pair of standing seams engages the extruded convex plastic panel with a pair of connector assemblies which connect the extruded convex plastic panel to the metal roof system. The pair of standing seams is configured to have a size and geometry to mate the pair of connector assemblies. Each of the pair of standing seams includes a plurality of ribs dividing a space delimited by the pair of standing seams into a plurality of subspaces. The pair of standing seams further includes a single or multi-tooth lock either on inside face or outside face of the pair of standing seams.

The pair of connector assemblies include a vertical base portion, an U-shaped protruding portion provided on top side of the vertical base portion integrally with and extending away from the vertical base portion. The U-shaped protruding portion includes a left leg, a right leg and an inclined central portion connecting the left and right legs. Each of the pair of connector assemblies further includes a single or multi-tooth flange provided on either left or right legs based on the single or multi-tooth lock provided either on inside face or outside face of the pair of standing seams respectively.

In an embodiment, the extruded convex plastic panel is locked with the pair of connector assemblies by pushing the pair of standing seams inside the pair of connector assemblies.

In an another embodiment, the rib structure is selected from the group of X, honey comb, twin cell or multi cell structure.

In an another embodiment, the extruded convex plastic panel includes protruding portions provided along two opposite side edges of the light transmitting member and projecting downward from the light transmitting member.

In yet another embodiment, the pair of connector assemblies are made of an extruded aluminum and fixed on support structures of the metal roof system with fasteners or screws or rivets. The support structures are made of metal, preferably of steel or aluminum and are adapted to support mounting of the extruded convex plastic panel to the roof system.

In yet another embodiment, the extruded convex plastic panel is made of polycarbonate or any other light transmitting plastic material and may be transparent or translucent.

Additional aspects, advantages, features, and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments, construed in conjunction with the appended claims.

It will be appreciated that the features of the present disclosure are susceptible to being combined in various combinations without departing from the spirit and the scope of the disclosure, as defined by the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those skilled in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.

Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:

FIG. 1A-C illustrates different views of an extruded convex plastic panel in accordance with a first embodiment of the disclosure;

FIG. 2A-C illustrates different views of an extruded convex plastic panel in accordance with a second embodiment of the disclosure;

FIG. 3A-C illustrates different views of an extruded convex plastic panel in accordance with a third embodiment of the disclosure;

FIG. 4A-C illustrates different views of an extruded convex plastic panel in accordance with a third embodiment of the disclosure;

In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.

DETAILED DESCRIPTION OF EMBODIMENTS

The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.

FIG. 1A-C illustrates different views of an extruded convex plastic panel in accordance with the first embodiment of the disclosure. FIG. 1A illustrates an enlarged side view of a portion of an assembled extruded convex plastic panel, particularly illustrating the connection arrangements between the extruded convex plastic panel, a connection assembly, a support structure and a metal roof. FIG. 1B illustrates a sectional view of the extruded convex plastic panel and FIG. 1C illustrates a sectional view of the extruded convex plastic panel installed on the metal roof by connector assemblies.

As shown in FIG. 1A, the extruded convex plastic panel 100 comprises a light transmitting member 101 including a top layer 101A and a bottom layer 101B and is made of polycarbonate plastic. A rib structure 102 is disposed between the top layer 101. A and the bottom layer 101B. The rib structure 102 includes a horizontal rib 102A provided parallel to the top layer 101A (or bottom layer 101B) and a plurality of vertical ribs 102B connecting the top layer 101A and the bottom layer 101B. The rib structure 102 further includes a plurality of diagonal ribs 101C configured in an X-shaped pattern.

The extruded convex plastic panel 100 further includes a pair of standing seams 103 (only one shown in FIG. 1A) provided along two opposite side edges of the light transmitting member 101 and projecting downward from an outer surface of the bottom layer 101B at an angle other than 90 degree. Each of the pair of standing seams 103 includes a plurality of horizontal ribs 104A dividing a space delimited by the pair of standing seams 103 into a plurality of subspaces. Further, a multi-tooth lock 104B is provided on an outside face of each of the pair of standing seams 103. The standing seam 103 with the multi-tooth lock 104B forms a first engagement region for engaging the extruded convex plastic panel 100 with a connector assembly 105.

As further illustrated in FIG. 1A, a pair of connector assemblies 105 (only one shown in FIG. 1A) provided to connect the extruded convex plastic panel 100 to a metal roof system 118. The connector assembly 105 includes a vertical base portion 107 and a U-shaped protruding portion provided on an upper end of the vertical base portion 107 integrally with and extending away from the vertical base portion 107. The U-shaped protruding portion includes a left leg (or first leg) 108, a right leg (or second leg) 109 and an inclined central portion 110 connecting the left leg 108 and the right leg 109. There is also provided a multi-tooth flange 111, which is a bent portion formed by inwardly bending extension from an upper end of the right leg 109.

The U-shaped protruding portion with the multi-tooth flange 111 forms a second engagement region, which defines a chamber for receiving the first engagement region of the standing seam 103. The first and second engagement regions are configured to have a size and geometry to mate with each other, so as to mount the extruded convex plastic panel 100 on the metal roof system 118. The extruded convex plastic panel 100 is locked with each of the pair of connector assemblies 105 by pushing the first engagement region of each pair of standing seams 103 inside the chamber of the second engagement region of each pair of connector assemblies 105.

As it is seen further, each of the pair connector assemblies 105 is fixed to support structures 112 (only one shown) of the metal roof system 118 with one or more fastener, screws, rivets or any other such components. The support structure 112 is made of metal such as steel or aluminum and can have C-shaped profile or any other suitable metal profile. The support structure 112 is adapted to support mounting/installing of the extruded convex plastic panel 100 to the metal roof system 118 by fixing the connector assembly 105 to the metal roof system 118.

Turning now to FIG. 1B, a sectional view showing the complete extruded convex plastic panel 100. The pair of standing seams 103, 106 can be seen at two side edges of the light transmitting member 101 and projecting downward from the outer surface of the bottom layer 101B at an angle other than 90 degree.

FIG. 1C illustrates a sectional view showing the complete extruded convex plastic panel 100 installed on the metal roof system 118 by the pair of connector assemblies 105, 115. Each of the pair of standing seams 103, 106 is locked to their respective pair of connector assemblies 105, 115 by pushing down each of the first engagement regions of the pair of standing seams 103, 106 into chambers of each of the second engagement regions of the pair of connector assemblies 105, 115. It will be seen further that the pair connector assemblies 105, 115 are connected to support structures 112, 114 using fasteners 113, 116 respectively.

FIG. 2A-C illustrates different views of an extruded convex plastic panel in accordance with the second embodiment of the disclosure. FIG. 2A illustrates an enlarged side view of a portion of an assembled extruded convex plastic panel, particularly illustrating the connection arrangements between the extruded convex plastic panel, the connection assembly, the support structure and the metal roof. FIG. 2B illustrates a sectional view of the extruded convex plastic panel and FIG. 2C illustrates a sectional view of the extruded convex plastic panel installed on the metal roof by connector assemblies.

FIG. 2A depicts the extruded convex plastic panel 100 which is similar to that shown in FIG. 1A except the position of the standing seam 103, different rib structure 102 and the formation of the multi-tooth flange 111 and the multi-tooth lock 104B. The standing seam 103 is provided along two opposite side edges of the light transmitting member 101 and projecting downward from an outer surface of the bottom layer 101B at an angle other than 90 degree. As it can be observed from FIG. 2A, the standing seam 103 is located offset at an offset distance from the two opposite side edges of the light transmitting member 101.

The rib structure 102 includes two horizontal ribs 102A provided parallel to the top layer 101A (or bottom layer 101B) and a plurality of vertical ribs 102B connecting the top layer 101A and the bottom layer 101B. The rib structure 102 forms a three cell structure, where each of the three cells in the three cell structure connected in parallel. As seen further in FIG. 2A, the multi-tooth lock 104B is provided on the inside face of the standing seam 103 and accordingly the multi-tooth flange 111 is provided on the left leg 108.

FIG. 2B illustrates a sectional view showing the complete extruded convex plastic panel 100 of FIG. 2A and FIG. 2C illustrates a sectional view showing the complete extruded convex plastic panel 100 of FIG. 2A installed on the metal roof system 118. Each of the pair of standing seams 103, 106 as shown in FIG. 2B is located offset at the offset distance ‘D1’ from the two opposite side edges of the light transmitting member 101.

FIG. 3A-C illustrates different views of an extruded convex plastic panel in accordance with the third embodiment of the disclosure. FIG. 3A illustrates an enlarged side view of a portion of an assembled extruded convex plastic panel, particularly illustrating the connection arrangements between the extruded convex plastic panel, the connection assembly, the support structure and the metal roof. FIG. 3B illustrates a sectional view of the extruded convex plastic panel and FIG. 3C illustrates a sectional view of the extruded convex plastic panel installed on the metal roof by connector assemblies;

FIG. 3A depicts the extruded convex plastic panel 100 which is similar to that shown in FIG. 2i \ except having different rib structure 102 and protruding portions 117A (only one shown). The rib structure 102 having a horizontal rib 102A provided parallel to the top layer 101A (or bottom layer 101B) and a plurality of vertical ribs 102B connecting the top layer 101A and the bottom layer 101B. The rib structure 102 forming a two cell structure, where each of the two cells in the two cell structure connected in parallel. The extruded convex plastic panel 100 also includes protruding portions 117A provided along two opposite side edges of the light transmitting member 101 and projecting downward from an outer surface of the bottom layer 101B of the light transmitting member 101.

FIG. 3B illustrates a sectional view showing the complete extruded convex plastic panel 100 of FIG. 3A, where it can be seen how protruding portions 117A, 117B are provided along two opposite side edges of the light transmitting member 101. As is also seen, each of the pair of standing seams 103, 106 is located offset at the offset distance ‘D2’ from the two opposite side edges of the light transmitting member 101. FIG. 3C illustrates a sectional view showing the complete extruded convex plastic panel 100 of FIG. 3A installed on the metal roof system 118.

FIG. 4A-C illustrates different views of an extruded convex plastic panel in accordance with the third embodiment of the disclosure. FIG. 4A illustrates an enlarged side view of a portion of an assembled extruded convex plastic panel, particularly illustrating the connection arrangements between the extruded convex plastic panel, the connection assembly, the support structure and the metal roof. FIG. 4B illustrates a sectional view of the extruded convex plastic panel and FIG. 4C illustrates a sectional view of the extruded convex plastic panel installed on the metal roof by connector assemblies;

The fourth embodiment as shown in FIG. 4A differs from the second and third embodiments in that the standing seam 103 is located offset with an offset distance from the two opposite side edges of the light transmitting member 101, where the offset distance is greater than the offset distances of the second and third embodiments. Additionally, the position of the support structure 112 is reversed, in that the support structure 112 is positioned on the right hand side of the standing seam 103.

FIG. 4B illustrates a sectional view showing the complete extruded convex plastic panel 100 of FIG. 4A. Each of the pair of standing seams 103, 106 is located offset with the offset distance ‘D3’ from the two opposite side edges of the light transmitting member 101. As it can be observed from FIG. 4B, the offset distance ‘D3’ is greater than the offset distances ‘D1’ and ‘D2’ of FIG. 2B and FIG. 3B respectively. FIG. 4C illustrates a sectional view showing the complete extruded convex plastic panel 100 of FIG. 4A installed on the metal roof system 118.

In the illustrated embodiments, the offset distances D1, D2, and D3 might vary and can be selected depending on the desired configuration of the metal roof system 118.

The second, third and fourth embodiments have the additional advantage of draining off excess water on the metal roof system 118 without getting inside the connector assemblies 105, 115. The configuration of the multi-tooth lock 104B on inside face of each of the pair of standing seams 103, 106 in these embodiments, the protrusion portions 117A, 117B are provided along two opposite side edges of the light transmitting member 101 in the third embodiment and further the position of the pair of standing seams with a greater offset distance ‘D3’ in the fourth embodiment prevents staging of any excess water on the metal roof system 118 by avoiding its entry inside the connector assemblies 105, 115.

Although the present invention uses polycarbonate for the preparation of the light transmitting member 101, but any other transparent or translucent light transmitting plastic material could also be considered for making such light transmitting member. Also embodiments of the invention mention usage of X, honey comb, twin cell or multi cell structure for the rib structure 102, any other commonly used rib structures such as parallel, diagonal, triangular, trapezoidal, diamond shaped or any combination thereof may be used without departing from the scope of the invention.

In the preferred embodiments of this invention, although the multi-tooth lock 104B and the multi-tooth flange 111 are illustrated, the single-tooth lock and the single-tooth flange can be employed instead.

While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. It will be apparent to persons skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. 

1. An extruded convex plastic panel (100) for use in a metal roof system (118), said extruded convex plastic panel (100) comprising: a light transmitting member (101) having a top layer (101A) and a bottom layers (101B) and a rib structure (102) disposed between said top and bottom layers (101A, 101B); a pair of standing seams (103, 106) provided along two opposite side edges of the light transmitting member (101) and projecting downward from the bottom layer (101B), wherein each of the pair of standing seams (103, 106) is located offset at an offset distance from the two opposite side edges of the light transmitting member (101); a single or a multi-tooth lock (104B) provided either on inside face or outside face of each of the pair of standing seams (103, 106); a pair of connector assemblies (105, 115), wherein each of the pair of connector assemblies (105, 115) having a vertical base portion (107) and a U-shaped protruding portion provided on an upper end of said vertical base portion (107) integrally with and extending away from said vertical base portion (107); a single or multi-tooth flange (111), corresponding to the single or multi-tooth lock (104), provided on the U-shaped protruding portion of each of the pair of connector assemblies (105, 115), wherein the single or a multi-tooth locks (104B) of each of the pair of standing seams (103, 106) engage with the single or multi-tooth flanges (111) of each of the pair of connector assemblies (105, 115) and the vertical base portion (107) is fixed to support structures (112, 114) of the metal roof system (118) for connecting the extruded convex plastic panel (100) to the metal roof system (118).
 2. The extruded convex plastic panel (100) as claimed in claim 1, wherein the offset distance is based on the position of the support structures (112, 114) in the metal roof system (118).
 3. The extruded convex plastic panel (100) as claimed in claim 1, wherein the rib structure (102) is selected from the group comprising X shaped structure, honey comb shaped structure, twin cell shaped structure, multi cell shaped structure, parallel shaped structure, diagonal shaped structure, triangular shaped structure, trapezoidal shaped structure, diamond shaped structure or any combination thereof.
 4. The extruded convex plastic panel (100) as claimed in claim 1, wherein the pair of standing seams (103, 106) is projecting downward from the outer surface of the bottom layer (101B) at an angle other than 90 degrees.
 5. The extruded convex plastic panel (100) as claimed in claim 1, wherein the first engagement region of each pair of standing seams (103, 106) further includes a plurality of horizontal ribs (104A) dividing a space delimited by the pair of standing seams (103, 106) into a plurality of subspaces.
 6. The extruded convex plastic panel (100) as claimed in claim 1, wherein the pair of standing seams (103, 106) have a size and geometry to mate with the U-shaped protruding portions of the pair of connector assemblies (105, 115).
 7. The extruded convex plastic panel (100) as claimed in claim 1, wherein said U-shaped protruding portion comprises a left leg (108), a right leg (109) and an inclined central portion (110) connecting said left and right legs (108, 109), and wherein the single or multi-tooth flange (111) is provided on either left or right legs (108, 109) corresponding to the single or multi-tooth lock (104) provided either on the inside face or the outside face of the pair of standing seams (103, 106).
 8. The extruded convex plastic panel (100) as claimed in claim 6, wherein the pair of standing seams (103, 106) is pushed into the U-shaped protruding portions of the pair of connector assemblies (105, 115) to connect the extruded convex plastic panel (100) to the metal roof system (118).
 9. The extruded convex plastic panel (100) as claimed in claim 1, wherein the pair of connector assemblies (105, 115) are made of an extruded aluminum and the vertical base portion (107) thereof is fixed to support structures (112, 114) of the metal roof system (118) with at least one fastener or screw or rivet (113, 116).
 10. The extruded convex plastic panel (100) as claimed in claim 1 further comprising protruding portions (117A, 117B) provided along two opposite side edges of the light transmitting member (101) and projecting downward from the bottom layer (101B) of the light transmitting member (101).
 11. The extruded convex plastic panel (100) as claimed in claim 1, wherein the support structures (112, 114) are made of metal and are adapted to support mounting of the extruded convex plastic panel (100) to the metal roof system (118).
 12. The extruded convex plastic panel (100) as claimed in claim 1, wherein the light transmitting member (101) is made of polycarbonate or any other light transmitting transparent or translucent plastic material. 